How ChillMate Works.
ChillMate is a Patent Pending
Pre-Cooling Water Treatment system which
acts either as a stand alone system or
as an adjunct to the TowerMate System.
ChillMate actually marries three or four
technologies (depending on the
application) - a Solids Separator, a Two
Auxiliary Magnetic Field Generator (MFG’s)
Biocide Co-Generator (BCG) and a
Pre-cooling Misting System (ChillMate)
which is enhanced by an ASHREA approved
Filtration Fabric System.

Biocide Co-Generator and MFG’s.
These two devices are provided in two
different water treatment technologies:
One which is controlled by a computer
Chip…a technology originally developed
by NASA. As conductive water in the
system passes over proprietary
electrodes, it accepts charged
molecules, or ions. And unlike UV,
ozone, and all other oxidizers, these
double positive ions provide
long-lasting residual protection. The
other is our integrated and auxiliary
MFG system, a Globally proven technology
which is a both a Biocide and Scale
inhibiting device solution.

When the BCG is powered on with our pump
which circulates the flow of the cooling
system water, the charged ions are
attracted to other molecules. When
these ions become attached to algae,
bacteria, and viruses the cells die
within minutes. The dead algae,
bacteria and virus cells, now much
larger, are easily filtered out of the
water. Even Legionnaires’ Disease is
eliminated.

MFG De-Scaler and
Corrosion Inhibitor.
Scale is caused when
minerals dissolved in
water precipitate out of
solution, forming a hard
mineral coating
(calcite) on heat
transfer surfaces and
pipes. The ChillMate
system employs an
intense system of MFG’s
which generate magnetic
flux fields that cause
calcite to revert to
aragonite, its natural
form. This prevents
scale formation and, in
fact, de-scales existing
surfaces without making
the water corrosive.

Corrosive water is
characterized by an
excess of hydrogen ions.
The ChillMate system
neutralizes this excess
and buffers the pH,
eliminating general
corrosion and the
galvanic corrosion
(pitting) that it can
cause. Chemically, the
water will appear
scaling (the opposite of
corrosive), but physical
forces prevent scale
formation.

Solids-From-Liquid
Separator.
This element of the
ChillMate system
provides continual
removal, down to 40
microns, of sand, silt,
pollen, and debris that
enter via air and makeup
water flow. It also
traps the scale that is
removed from heat
transfer surfaces. The
separator contains no
filter medium, and there
are no moving parts. No
backwashing is required,
either. Accumulated
solids are automatically
purged periodically with
a water loss of only 1-4
quarts.

Cooling Tower Intake
Filtration Fabric.
Failure to provide
effective air intake
protection to building
or equipment fans,
motors, heat exchangers
and other process
cooling systems adds up
to a costly loss of
productivity in safe and
efficient system
operations. The
ChillMate Equipment
Protection Filters are
made of permanent,
washable polypropylene.

As a primary
pre-filtration defense,
they help prevent the
damage and extensive
maintenance that large
volumes of debris can
cause. Custom sized to
fit any air intake, the
fabric is UV protected
and stands up to extreme
outdoor exposure,
corrosive environments,
high velocity air flow,
as well as industrial
cleaning and maintenance
handling. Our simple
solution to air intake
filtration helps reduce
operational and
maintenance costs over a
long useful life.

Pre-Cooling Misting
System.
The side stream
TowerMate pump system is
outfitted with an
additional high pressure
pump for providing
increased water
pressure. This is
required to feed the
evaporative nozzles
which create a
continuous cloud of both
a very fine mist, for
evaporative cooling of
the air and for keeping
the filtering fabric
constantly dampened with
moisture. The outer fill
components of the Tower
are keep clean of solids
and bio build-up due to
the treated water. The
cool moist air is pulled
through by the suction
fans thereby
supplementing the
evaporative cooling
process and saturating
the fill with treated
water that will attack
the bio-fouling
contaminants as well as
the scale producing
elements (silica and
lime). The cool filtered
and treated water is
supplied from the sump
basin thus eliminating
the need for additional
make-up water for the
misting system.

The air being drawn into
the Tower through the
fill is cooled by
between 20 and 30°F
which will enhance the
evaporative cooling
process of the tower and
will save at least 5-10%
on the Tower and Chiller
system energy since it
will aid significantly
by lowering the approach
temps. We also contend
that it will reduce some
evaporative water loss
since the
pre-evaporative mist
which is drawn in by the
fans will cool the water
in the fill thus
condensing the evaporate
back into a liquid as it
blends with the hot
water, some of which is
being pre-cooled enough
before it would have
reached the evaporation
point under the normal,
non pre-cooling
conditions (I.e. when
the normally hotter
water meets the normally
warmer air more
evaporative loss takes
place because more
heated evaporate is
given up at a more rapid
rate).

By extending the
evaporative cooling
environment of the Tower
to the large area
outside of the air
intake, we are
effectively expanding
the cooling capacity of
the tower by 30% or more
without increasing the
energy or space
requirements. We are
also reducing the
dramatic flux and
characteristics of the
phase changes by
enabling heat reduction
more so through
condensation rather than
exclusively by
evaporation. That is,
the outside nozzle mist
and evaporate is being
suctioned and recaptured
and converted back to a
liquid into the Tower
fill by the conductive
action of cool
convective moist air
rather than being given
off as steam or vapor.
Furthermore, as the hot
water entering the tower
meets with cool moist
air, it will blend and
cool conductively and
thus will give off less
evaporation through the
Tower exhaust fans.

One gallon of water has
~8,000 BTU of cooling
potential (heat of
vaporization). The more
efficiently water is
evaporated, the more of
its full cooling
potential can be
realized. The greater
the surface area, the
quicker it evaporates.
As stated above, when
the evaporate is
suctioned back as cool
mist the process becomes
even more efficient. Our
misting system uses
ultra low flow
atomization nozzles to
form a mist of fine
water droplets in µm
sizes (~1/10 of a strain
of hair) – 1 gal of
water has a surface area
greater than a Soccer
Field. On a 350 ton
Cooling Tower our high
pressure misting system
can put out over 200
gallons of mist per hour
which equates to over
200 soccer fields of
surface area or
1,600,000 BTU's of
cooling potential or the
equivalent of 133 tons
of added cooling
capacity. Once released
into air, water droplets
quickly absorb heat in
the ambient and
evaporate, thus cooling
the air. When the
incoming air is
pre-cooled by 30°F,
it is as if the CT has
the work load of a 70°
day rather than a 100°
day.
This allows the
Condenser and Chiller
(or Heat Exchangers) to
transfer heat much more
efficiently:

Head
pressure and
amperage
draw are
reduced

Output
temperature
is reduced

"Time-on”
cycles are
reduced

Energy
consumption
is reduced

Coefficient
of
performance
(COP) is
increased

Life
of condenser
is extended

Here are some
average test
results from
Evaporative
cooling:

¨
Compressor
head
pressure
reduction –
25%

Amperage
draw
reduction –
21%

Condenser
ambient
temperature
reduction –
28 °F

Exhaust
air
temperature
reduction –
12 °F

Chill-N-Save
Applications
(click
below)

In addition, as previously
mentioned, Axess1 has integrated
its own patent pending
co-generating bio and scale
terminator which operates with a
water recirculation feature that
super charges the misting water
with ionic charges that both
kills bacteria and algae as well
as to convert the water into a
de-scaling solution as it
combines with the air and enters
into the fill components of the
Tower. Since these added
components will serve to boost
the Cooling Tower cleaning, the
heat transfer efficiency of the
Tower will be Maintained at or
better than the factory optimal
efficiency specs, especially
when the ChillMate system is
combined with the TowerMate
system.